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Dec. 10, 1963 ETAL ITS

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Dec. 10, 1963 a. PHILLIPS E'rAL 3,113,434

ROOF 0F PANEL UNITS Filed Sept. 17, 1959 2 Sheets-Sheet 2 wml, MM@

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United States Patent O 3,113,434 ROUE' 0F PANEL UNHS Benjamin Phillips and David G. Phillips, Miami, Fla.,

assignors, by mesne assignments, to Reichhold Chemicals, Inc., White Plains, N.Y., a corporation of Delaware Filed sape. 17, 1959, ser. No. 840,699 4 claims. (ci. sti-s4) This invention relates to a moduler panel unit adapted for use in the construction of -roof decks, awnings, wind break panels, and the like, and is particularly directed to a panel lof this type embodying a sheet of a translucent corrugated plastic material, such as fiberglass.

In the past, it ha-s been proposed to use corrugated fiberglass panels in awning constructions and as roofs for porches, patios and the like. While these corrugated panels are advantageous in that ythey transmit a certain amount of light while blocking a large portion of the suns heat, the panels have not proved to :be completely satisfactory in this type of installation. Most of the difficulties with these panels are due to the fact that the panels were not primarily ydesigned for such uses. Rather, translucent fiberglass panels were originally designed for introduction into the roof or wall sections of industrial buildings covered with metal sidings. The fiberglass was corrugated to conform to the corrugations in the metal and the panels were dimensioned the same as corrugated metal panels sol that the fiberglass panel could be substituted for a metal panel wherever it was desired to provide a sky light or side light panel. However, when it was attempted to use these same panels yfor awnings, roof decks, and .the like, it was necessary to -resort to many makeshift methods of fabrication, assembly and installation. For example, in formi-ng a large roof deck panel it became conventional practice -to overlap at least two corrugations of each fiberglass panel and -to seal the lap with a suitable cement. Thereafter, the lap was securely nailed to `a supporting rafter or purlin disposed directly beneath the lap.

This particular construction has several disadvantages. In the first place, there is substantial loss of useful area of fiberglass material due to the substantial overlapping of adjacent panels. This, of course, materially increases the cost of an installation. Additionally, fiberglass panels do not have an appreciable amount of rigidity and are unable to support even small load-s, such as for example, a snow load on a roof deck. Consequently, these panels require the construction of an elaborate supporting framework of wood or metal. Moreover, the fasteners such as screws or nails which are employed to secure these panels to the underlying framework require the careful installation of rubber washers to seal the holes against leaks. This Iadds still more to the cost of 4the installation and after a period of time many installations do not remain watertight.

An additional major `disadvantage of this type of construction is that the exposed edges of the panels are unsightly and the surface coating :of the panels frequently tends to deteriorate rapidly near these exposed edges.

The present invention is directed to a modular fiberglass panel unit construction in which all of the foregoing difficulties are eliminated. vMore particularly, lthe present invention is predicated upon the concept of providing a modular panel unit comprising a corrugated translucent plastic sheet mounted in a surrounding metal frame, the frame being configurated for ready assembly with similar panel units to form roof decks, partitions, and many other structures.

One of the principal advantages of the present modular panel unit is that substantially all of the area of the fiberglass sheet is effectively employed. Moreover, the fiber- 3,1 13,434 Patented Dec. 10, 1963 ICC glass sheet is mounted in the surrounding metal frame without the use of met-al fasteners piercing the fiberglass panel. Additionally, the metal frame completely surrounds and protects the edges of the fiberglass panel so that the panel edges are protected against deterioration and a permanently water tight structure is provided.

Another advantage of the present panel unit is that the panel can be permanently assembled with the frame very quickly and without the use of any tools. More particularly, in the preferred embodiment, the .frame includes two side members formed of extruded aluminum. Each of these side members has an inwardly projecting curved flange conforming to the shape of the edgewise portions of the corrugated panel. When assembling the fiberglass sheet and frame, a thin adhesive strip of a synthetic rubber compound, or the like, is applied to the edgewise portions of the fiberglass sheet. These adhesive strips covered portions of the fiberglass sheet are then brought into contact with the curved flanges and are clamped in place `by means of la clincher strip which is wedged between the panel and a second flange on the side frame member.

Another advantage of the present modular panel unit is that the metal frame surrounding the fiberglass panel rigidifies the panel and completely eliminates the need for external reinforcing members, such as beams or the like. Moreover, the side edges of each panel are configurated to interlock with the side edges of adjacent panels to that these interlocked frame members in effect constitute internal lbeams within the structural unit.

Another important object of the invention is to provide modular panels which can be `assembled with one another and with supporting end members without the use of structural fasteners. The present panels can be interlocked together without the use of any tools. Moreover, the panels can be interlocked with their end supporting members without -any tools, except for a screw driver used -to tighten set screws to lock the panels in position. When so assembled, the panels provide a light transmitting unit, such as a deck or wall which is at the same time completely water proof. The present modular panel unit thus makes it a relatively simple matter for a homeowner unskilled in the use of tools to erect his own patio, car port roof, fence, or any one of many other useful structures with a substantial saving in both labor and material cost.

These and other objects and advantages of the present invention will be more readily apparent from the following detailed description of the drawings illustrating a preferred embodiment of the invention.

ln the drawings:

FIGURE 1 is a perspective view showing a preferred .form of rigid awning constructed in accordance with the presen-t invention.

FIGURE 2 is a perspective view of one component awning panel.

FIGURE 3 is a cross-sectional view taken along line 3-3 of FIGURE 1.

FiGURE 4 is a cross-sectional view taken along line 4 4 of FIGURE 2.

FIGURE 5 is la cross-sectional View taken along line 5 5 of FIGURE 4.

FGURE 6 is a cross-sectional view taken along line v6--t5 of FIGURE 1.

FIGURE 7 is a cross-sectional view taken alo-ng line 7-7 of FIGURE 1.

One preferred form of structure embodying the modular units of the presen-t invention is shown in FIGURE 1. As there shown, the modular units are assembled to form a roof deck 1i), or cover for a patio. It is to be understood, however, that this embodiment is merely exemplary and that the present modular panel units are equally useful in other structures such as rigid awnings, partitions, fences, wind break panels, and the like.

In the specific embodiment shown in FIGURE l, the roof deck comprises three modular panel units 1-1, 12 and 1'3 which are mounted in side-byside abutment and are carried by .a longitudinally extending hanger bar 14 secured to the wall of the building, and a longitudinally extending channel support member carried by a plurality of poles 16, or the like.

The details of con-struction of each modular p-anel unit and the manner in which they are joined together are best shown in FIGURES 3-5, while the manner in which the panels are mounted upon the hanger member 14 and channel support member 15 is best shown in FIGURES 6 and 7.

As is best shown in FIGURE 2, a component panel unit 11 constructed in accordance with the prese-nt invention comprises a corrugated translucent panel 17 formed of any suitable mate-rial, such as fiberglass. More particularly, panel 17 is of generally rectangular configuration and is made from a suitable rigid translucent fiberglass material, such as Alsynite The panel is provided with a series of parallel corrugations which Vpreferably extend length-wise of the sheet.

Panel 17 is mounted in a rectangular frame 1S. This frame comprises a female side member 261, a male side member 21, a front end member 22 and a rear end member 23. Each of these members is preferably formed of extruded aluminum, the members being rigidly interconnected in any suitable manner as by means of rivets 24.

The configuration of male frame member 21 and female frame member and the manner in which the fiberglass panel is mounted in these members is best shown in FIGURE 3. As is there shown, female member 20' is an elongated extruded aluminum frame member comprising a vertical wall portion 25 having two spaced apart inwardly facing upper and lower horizontal flanges respectively numbered 26 and 27. Upper flange 26 is spaced ldownwardly from the upper edge of wall portion 25. A horizontal flange -28 extends outwardly from the upper edge of wall portion 25 and terminates in a downwardly extending lip 30I effective to form ia channel 31 along the outer sur-face of the vertical wall portion 25. It is to be noted that the lower edge of lip 30 terminates above the upper surface of upper flange 26. Female frame member 201 .also includes an inwardly extending downwardly curved flange 312. Curved flange 32 is disposed intermediate upper flange 26 and lower flange 27 and is preferably of a radius substantially equal to the radius of corrugations 33 of panel 17.

-Male side frame member 21 is generally similar to female side frame member 20 and comprises an aluminum extrusion of the s-ame length as female side frame member 20. More particularly, male side member 21 comprises a -vertical wall portion 34, upper and lower inwardly extending horizontal flanges Iand 36, and an arcuate inwardly facing and downwarding turned flange 37 disposed intermediate flanges 35 and 36. As is apparent from 'FIGURE 3, both lower flange 32 of the female side member 20i and flange 37 of the male side frame member 21 extend horizontally along the lower edge of wall portions 64 and 25'. Upper flange 35 and curved flange 37 of the male side frame member 2f) are respectively spaced from lower flange 36 the same distances that upper flange 26 and curved flange 32 are spaced from lower flange A27 of the female side frame member 20. ASide wall mamber 34 extends upwardly above upper flange 35 to form an upwardly extending lip. p 'The heightof thislipis just sufficient to be received withinchaiinel 31 of" the female side framemember 20 when lower flanges 2.7 rand 36 of the female and male members lare in horizontal alignment as shown in FIG- URE 3.

The corrugated panel 17 is held in engagement with each of the side panels 2f) and 21 by means of clincher angle members 38. 'Each of the clincher angle members is preferably formed of extruded aluminum and is of a length slightly less than the length of the side members. Clincher langle member 38` includes a pivot arm 4t) and a curved flange 41. The curvature of flange 41 is preferably substantially the same as the curvature of curved flanges 32 and 37 of the side frame members and the width of this flange is substantially the same as the width of flanges 32 and 37.

In assembling a fiberglass panel 17 with side frame members 20 and 21, the upper side edges of the corrugated panel are first covered with a thin sealing strip, one suitable form of strip comprising a cloth mesh covered with a pliable synthetic rubber sealing compound. The curved flanges y32. and 37 are then brought into contact with the sealing strips covering the edges of the panel and a clincher `angle member 38 is inserted in the position shown by dotted lines in FIGURE 5. As there shown, the lower edge 42 of pivot arm lil of clincher angle member 38 is brought into engagement with the corner between lower flange 36 and side wall 34 of male frame member 21. The arcuate lip 41 of clincher member 38 engages the lower surface of the endwise corrugations of panel member 17. Thereafter, the clincher member is pivoted in a counterclockwise direction as viewed .in FIGURE 5 to bring the edge 43 of the arcuate lip 41 into engagement with wall 34 of male member 21. As the clincher member is pivoted in this manner, the sealing strip 39 is compressed so that the edges of panel 17 tightly clamp in place and a waterproof joint is formed along the longitudinal edges of the panel. A second clincher member 38- is inserted in the same manner in `female member 50 to secure the panel 17 to that member.

The front and rear end members 22 and 23 of the frame are identical and are best shown in FIGURES 4, 6, and 7. As is there shown, each of the front and rear members comprises a vertical wall portion 44, an inwardly turned upper flange 45 extending at right angles to wall 44 at the upper edge thereof, and an inwardly turned lower flange 46 preferably of substantially the same length as flange 45. Flange 46 extends inwardly parallel from flange 45 and is spaced upwardly from the lower edge of wall 44 whereby the lowermost portion of the wall forms a depending lip 47. The lowermost edge of this lip is provided with a widened portion 48 forming a narrow shoulder 49. Disposed between flanges 45 and 46 are two inwardly extending spaced intermediate flanges 50 and 51. Flange 51 extends substantially the full length of the end member, while flange 50 is slightly shorter than the end member to accommodate the arcuate flanges of the side members. These flanges are spaced apart a distance substantially equal to the maximum height of the corrugated panels and form with the adjacent portion of wall 44 a panel receiving channelSZ adapted to receive the front end and rear end of panel 17. A suitable calking compound can be inserted in this channel in contact with fiberglass panel 17 to form a water tight joint if desired. However, when the modular panel units are adapted to be used in a roof construction, as is shown in FIGURE l, front end member 22 is preferably provided with a series of spaced openings 53 between flanges 50 and 51. These openings are preferably aligned and spaced above the low points or troughs 54 (see FIGURE 5) of the corrugated panel so that the water after running down the panel passes through the openings 53 and thus discharges from the panel.

As is best shown in FIGURES 3 and 4, when the front and rear frame members 22 and 23 are joined to the female and male side members 20 and 21, the lowermost flanges 36 and 27 of the side frame members engage the lower portions of lower flange 46 from the front and rear end members. In a similar manner, the

upper flanges 26 and 35 of the side members engage the upper flanges 45 of the front and rear members. As is explained above, these engaging flanges are secured together in any suitable manner, such as by means of rivets 24 to form a rigid rectangular frame.

In the completed roof deck shown in FIGURE 1, three component panel units 11, 12, and 13 are assembled together in side by side abutment. As is best shown in FIGURE 3, the male frame member 21 of component panel 11 abuts the female member 20 of component panel 12 with the upwardly extending lip portion of wall 34 of the male frame member residing within channel 31 of the female frame member. Panels 12 and 13 are assembled in the same manner.

The rear frame member 23 of each of the panel units is disposed with the depending lip 47 resting in upwardly facing channel 55 of hanger member 14. As is best shown in FIGURE 7, hanger member 14 is secured to the building wall in any suitable manner, such as by means of screws 56. The hanger includes a vertical wall 57 which abuts the building wall, the lower edge of the hanger being upturned to form channel 55. A plurality of set screws 58 threadably engage arm 59 of the channel and depending lip 47 of the rear frame member 23. These set screws engage the depending lip 47 above shoulders 48, and thereby prevent upward disengagement of the rear member from the hanger.

In a similar manner, the front frame members 22 are disposed within channel support member 15. The front channel support member 15 includes a front Vertical strip 60, a horizontal bottom strip 61, and an inner upwardly turned strip 62 defining a channel 63. The front channel member 15 is mounted upon posts 16 by means of angle brackets 64 which are bolted to the channel member as by means of bolts 65 and to posts 16 as by means of bolts 66. Channel member 15 is preferably dimensioned so that front strip 6l) is as high as front frame members 22 of the component panels. Inner strip 62 of the channel carries a plurality of set screws 67 which are disposed to engage the downwardly depending lip 47 of the front frame members above shoulder 49. Set screws 67 and 53 thus function to lock the panels tightly in place.

Front channel member 15 performs a second function in addition to supporting the lower end of the component panels. As is best shown in FIGURE 6, drain openings 53 formed in front frame members 22 are disposed above channel 63. Consequently, water discharged through these openings drops into the channel 63 which thus functions as a drain gutter and conveys the water to one side of the roof.

In actual use, the component panels, such as panels 11, 12, and 13, are prefabricated at the factory and are shipped to the user together with posts 16 and a hanger member 14 and channel support member 15 of the proper length. The homeowner or workman then fastens hanger member 14 to the building wall, erects posts 16 and bolts channel member 15 to the posts. Thereafter, the component panels are interlocked and mounted on the channel member and hanger member as shown in FIG- URE 1. Finally, the set screws 53 and 67 are tightened to lock the panels firmly in place. Thus, the entire deck can be assembled with only a screw driver and a pair of pliers or a wrench. When installed, the deck needs no other external supporting members even though the deck is subjected to snow loads or the like. The rigid panels are self-supporting, with the interlocked male and female members functioning as beams or rafters.

From the foregoing disclosure of the general principles of the present invention and the above description of a preferred embodiment, those skilled in the art will readily comprehend various modifications to which the invention is susceptible. Therefore, we desire to be limited only by the scope of the following claims.

Having described our invention, we claim l. A water-tight roof comprising la plurality of modular panel units in side-by-side abutment, each of said modular panel units comprising a sheet: of corrugated translucent plastic material, said sheet having longitudinal edges parallel to the corrugations, a metal frame surrounding said sheet, means carried by said frame for clamping engagement with the opposed longitudinal edges of said corrugated sheet, each of sai-d frames including an upper end member, a lower end member and two opposite side members, one of said side members having an upstanding lip, the other of said side members having a downwardly opening channel portion, the lip on the side member of one modular panel unit being inserted within the channel portion of the adjacent panel unit, whereby said panel units are interlocked against transverse movement, the upper and lower end members having depending lianges, each of said flanges on the lower end members having a shoulder formed thereon, `a hanger member including a channel receiving and supporting the depending langes of said upper end members, and a channel support member receiving and supporting the anges of said lower end members, locking means carried by said channel support members and disposed Ifor engagement with said shoulders for locking said panel units against longitudinal movement.

Q. A Water-tight roof comprising a plurality of modular panel units in side-by-side abutment, each of said modular panel units comprising a sheet of corrugated translucent plastic material, said sheet having longitudinal edges parallel to the corrugations, a metal frame surrounding said sheet, means carried by said frame for clamping engagement with the opposed longitudinal edges of said corrugated sheet, each of said frames including an upper end member, a lower end member `and two opposite iside members, one of said side members having an upstanding lip, the other `of said side members having a downwardly opening channel portion, the lip on the side member `of one modular panel unit being inserted within the channel portion of the adjacent panel unit, whereby said panel units are interlocked against transverse movement, the upper and lower end members having depend ing flanges, each of said lianges on the lower end members having a shoulder formed thereon, a. hanger member including a channel receiving and supporting the depending flanges of said upper end members, and an upwardly opening channel support member receiving and supporting the flanges of said lower end members, locking means carried by said channel support members and disposed for engagement with said shoulders for locking said panel units against longitudinal movement, said lower end members including drain openings disposed above said sheets land communicating with said channel member Iwhereby said channel member also functions as a gutter.

3. A water-tight roof comprising a plurality of modular panel units in side-by-side abutment, each of said modular panel units comprising a sheet of corrugated translucent plastic material, said sheet having longitudinal edges parallel to the corrugations, a metal frame surrounding said sheet, means carried by said frame for clamping engagement with the opposed longitudinal edges of said corrugated sheet, each of said frames including an upper end member, a lower end member Iand two opposite side members, one of said side members having an upstanding lip, Ithe other of said side members having a downwardly opening channel portion, the lip on the side member of one modular panel unit being inserted within the channel of the adjacent panel unit, whereby said panel units rare interlocked against transverse movement, the upper and lower end members having depending flanges, each of said flanges on the lower end members having a shoulder formed thereon, a hanger member including a channel receiving and supporting the depending flanges of said upper end members, and a channel support member receiving and supporting the flanges of said lower end members, and a plurality of set screws carried by said channel support member in abutment with the shoulders on the depending flanges disposed within said channel, whereby said panel units a-re locked against longitudinal movement.

4. A water-tight roof comprising a plurality of modular panel units in side-by-si-de abutment, each of said modular units comprising a sheet `of corrugated translucent plastic material, said sheet having longitudinal edges par- -allel to the corrugations, a metal frame surrounding said sheet, said frame comprising lan upper end member, a lower end member and two opposite side members, means carried by said frame for clamping engagement with the opposed longitudinal edges of said corrugated sheet, said last named means comprising inwardly extending curved flanges respectively disposed `on opposite 'sides of said frame overlying said corrugated sheet in Contact with the longitudinal edgewise portions of sai-d corrugated sheet, and clamping members disposed beneath said sheet in lrespective engagement with the longitudinal edgewise portions of said sheet, each of said clamping members being generally L shaped and having an arcuate flange and an arm portion extending outwardly from said ange, each side of said frame being provided with an abutment spaced downwardly from said curved flange, the lowermost edge of Ithe arm portion of each of said clamping members residing in pivotal engagement with said abutment, the arcuate ange of each of said clamping members residing in engagement with said corrugated sheet, said corrugated sheet being clamped between the curved anges on said frame and `the ilanges of said clamping members, one of said side members having an upstanding lip, the other of said side members having a `downwardly opening channel portion, the lip on Ithe side member `of one modular panel unit being inserted within the channel of the adjacent panel unit, whereby said panel units are interlocked against transverse movement, the upper tand lower end members having depending ilanges, each of said flanges having a shoulder formed thereon, a hanger member including -a channel receiving and supporting the depending flanges of said upper end members, and la channel support member receiving and supporting the flanges of said lower end members, and a plurality of set screws carried by 4said channel support member in abutment with the shoulders on the depending flanges `disposed within said channel of said support member, whereby said panel units are locked against longitudinal movement.

References Cited in the iile of this patent UNITED STATES PATENTS 409,916 Caldwell Aug. 27, 1889 1,239,421 Metzger Sept. 4, 1917 1,476,931 Sylvan t Dec. 11, 1923 1,656,044 Cibulas Jan. 10, 1928 1,740,749 Shuman Dec. 24, 1929 1,931,750 Blaski Oct. 24, 1933 2,175,653 Williams Oct. 10', 1939 2,269,656 Fowler Jan. 13, 1942 2,396,829 Carpenter Mar. 19, 1946 2,484,987 Eschrich Oct. 18, 1948 2,611,454 Arehart et al Sept. 23, 1952l 2,752,643 Helt et al. Iuly 3, 1956 2,811,935 Jones Nov. 5, 1957 2,874,653 Ratner Feb. 24, 1959 2,883,946 Kleef Apr. 28, 1959 2,942,704 Stubbs June 28, 1960 2,969,618 Ratner et al Jan. 31, 19611 FOREIGN PATENTS 202,850 Great Britain Aug. 30, 1923 

1. A WATER-TIGHT ROOF COMPRISING A PLURALITY OF MODULAR PANEL UNITS IN SIDE-BY-SIDE ABUTMENT, EACH OF SAID MODULAR PANEL UNITS COMPRISING A SHEET OF CORRUGATED TRANSLUCENT PLASTIC MATERIAL, SAID SHEET HAVING LONGITUDINAL EDGES PARALLEL TO THE CORRUGATIONS, A METAL FRAME SURROUNDING SAID SHEET, MEANS CARRIED BY SAID FRAME FOR CLAMPING ENGAGEMENT WITH THE OPPOSED LONGITUDINAL EDGES OF SAID CORRUGATED SHEET, EACH OF SAID FRAMES INCLUDING AN UPPER END MEMBER, A LOWER END MEMBER AND TWO OPPOSITE SIDE MEMBERS, ONE OF SAID SIDE MEMBERS HAVING AN UPSTANDING LIP, THE OTHER OF SAID SIDE MEMBERS HAVING A DOWNWARDLY OPENING CHANNEL PORTION, THE LIP ON THE SIDE MEMBER OF ONE MODULAR PANEL UNIT BEING INSERTED WITHIN THE CHANNEL PORTION OF THE ADJACENT PANEL UNIT, WHEREBY SAID PANEL UNITS ARE INTERLOCKED AGAINST TRANSVERSE MOVEMENT, THE UPPER AND LOWER END MEMBERS HAVING DEPENDING FLANGES, EACH OF SAID FLANGES ON THE LOWER END MEMBERS HAVING A SHOULDER FORMED THEREON, A HANGER MEMBER INCLUDING A CHANNEL RECEIVING AND SUPPORTING THE DEPENDING FLANGES OF SAID UPPER END MEMBERS, AND A CHANNEL SUPPORT MEMBER RECEIVING AND SUPPORTING THE FLANGES OF SAID LOWER END MEMBERS, LOCKING MEANS CARRIED BY SAID CHANNEL SUPPORT MEMBERS AND DISPOSED FOR ENGAGEMENT WITH SAID SHOULDERS FOR LOCKING SAID PANEL UNITS AGAINST LONGITUDINAL MOVEMENT. 